Part 1

Engine

Special Tool(s):

Special Tool(s):

General Equipment:

Disassembly (Steps 1-44)

CAUTION: If the fuel rail is used as a leverage device, damage can occur to the fuel rail. Care must be taken when working around the fuel rail.





1. Remove the flywheel or flexplate.





2. Using the special tool, remove the crankshaft rear seal.
3. Install the engine on a suitable engine stand.
4. Remove the floor crane, Spreader Bar and the Engine Lifting Brackets.





5. Remove the generator mounting bracket.
1. Remove drive belt tensioner bolt.
2. Remove the generator mounting bracket bolts.





6. Disconnect the idle air control (IAC) valve, throttle position (TP) sensor electrical connectors and the TP sensor wiring pin-type retainer.





7. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and tube fitting.





8. Disconnect the EGR vacuum regulator solenoid valve electrical and vacuum connections.





9. Disconnect the camshaft position (CMP) sensor and differential pressure feedback EGR system electrical connectors. Release the wiring harness pin-type retainer.





10. Remove the bolt and disconnect the radio ignition interference capacitor electrical connector.





11. CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.

Using the special tool, remove the spark plug wires from the spark plugs and all routing clips.





12. Disconnect the ignition coil electrical connector.





13. Remove the ignition coil bracket lower bolts.





14. Remove the ignition coil bracket upper bolts and the ignition coil assembly.





15. Disconnect the vacuum hoses.





16. Detach the pin-type retainer and disconnect the knock sensor electrical connector.





17. Remove the intake manifold bolts and lift up the intake manifold.





18. Remove the heated positive crankcase ventilation (PCV) hose retainers and remove the heated PCV fitting.
19. Remove the intake manifold.





20. Disconnect the coolant hose.





21. Remove the coolant tube bracket retaining bolts.





22. Disconnect the coolant hoses.





23. Detach the wiring harness retainer and remove the coolant tube and bracket assembly.





24. Disconnect the crankshaft position (CKP) sensor electrical connector.





25. Remove and discard the wiring anchors.





26. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.





27. NOTE: LH shown, RH similar.

Disconnect the 6 fuel injector electrical connectors.





28. Remove the fuel charging wiring harness.





29. Disconnect and remove the EGR tube from the exhaust manifold.





30. Remove the fuel supply tube upper bracket bolt.





31. Remove the fuel supply tube lower bracket bolt.





32. Remove the fuel rail bolts, fuel rail and the fuel injectors as an assembly.





33. Disconnect the PCV hose.





34. Remove the PCV valve from the valve cover. Remove the PCV system from the engine.





35. Remove the LH valve cover and the gasket.





36. Remove the RH valve cover and the gasket.





37. Remove the thermostat housing.
1. Remove the bolts.
2. Release the bypass hose clamp and remove the housing.





38. Remove the bolt and the oil level indicator tube.





39. Remove the bolt and the knock sensor (KS).





40. Remove the nuts, LH exhaust manifold and the gasket.
^ Discard the nuts and gasket.
41. Remove and discard the 6 LH exhaust manifold studs.





42. Remove the nuts, RH exhaust manifold and the gasket.
^ Discard the nuts and gasket.
43. Remove and discard the 6 RH exhaust manifold studs.





44. Remove the bolts and the coolant pump.